Dispenser for swabs

ABSTRACT

A swab dispensing carton is provided which includes a housing defining a hollow receiving space and a drawer disposed within the receiving space, and containing multiple rows of swabs. The housing includes a pair of first side walls, a pair of second side walls, and a closure panel covering one end of the receiving space and being opposite an open mouth. The drawer includes a pair of first side panels, a pair of second side panels, and a floor opposite a dispensing opening. The floor is provided with at least three interleaved flaps having a strength to resist a pressure of at least 30 pounds of force. The dispensing opening is oriented to face one of the first or second side walls of the housing.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention concerns a container for storing multiple layers of swab articles in a protective system for their dispensing.

2. The Related Art

Swabs are articles having an absorbent covering on at least one end of an elongated stem. Cotton is generally used as the absorbent covering. Stem materials are often of wood, rolled paper or plastic. Conventional swabs are typically constructed by applying the absorbent covering directly to the distal ends of the stem.

A variety of containers have been used to dispense swab articles. A major consideration for an appropriate container is one that can keep the absorbent tip clean. Contamination from dust and microbes must be minimized. Nonetheless, the protective measures should not interfere with a consumer's ability to withdraw a swab from the container.

Packaging systems are known which have sought to solve these problems. One example is found in U.S. Pat. No. 5,938,026 (Thorn). A reclosable dispenser is provided which includes an outer case having a cap hingedly attached to a rear wall of the case. A tray is fitted within and slidably removable from a pocket of the case. The reclosable dispenser serves as a travel case carrying relatively small numbers of the swabs. These are laid within the tray but protected by the relatively thick walled outer case.

U.S. Pat. No. 5,549,200 (Cowan et al.) reports another swab dispenser system. It includes a reusable outer receptacle and a replaceable refill container insertable therewithin. Benefit of this system is the multiple layers of swabs that can be stored. Unfortunately this system tends to expose a significant number of the swabs during a single dispensing event.

An advantage of the present invention is being not limited to travel amounts of swabs while protecting from contamination all but a top few during any single dispensing event.

SUMMARY OF THE INVENTION

A swab dispensing carton including:

-   -   a housing defining a hollow receiving space and including a pair         of parallel oppositely disposed first side walls, a pair of         second side walls orthogonally oriented to the first side walls,         a closure panel covering one end of the receiving space and at         an opposite end an open mouth defined by upper edges of each of         the first and second side walls;     -   a drawer disposed within the hollow receiving space of the         housing, the drawer including a pair of parallel oppositely         disposed first side panels, a pair of second side panels         orthogonally oriented to the first side panels, a floor         orthogonally oriented to each of the first and second side         panels, the floor including at least three interleaved flaps,         the first and second side panels having respective upper edges         defining a dispensing opening, the opening being juxtaposed         opposite the floor;     -   an array of swabs arranged within a cavity of the drawer; and     -   wherein the floor has a strength to resist a pressure of at         least 30 pounds of force, the drawer being slideably movable         from an open to a closed position, the open position having the         drawer partially outside the receiving space, and the dispensing         opening being oriented to face one of the first or second side         walls.

BRIEF DESCRIPTION OF THE DRAWING

Further advantages, features and structures of our invention can be more fully appreciated from consideration of the drawing in which:

FIG. 1 is a perspective view of the swab dispensing carton illustrating the drawer in an open position partially outside the housing;

FIG. 2 is a cross-sectional view along line 2-2 of FIG. 1 showing an internal surface of a first wall of the housing;

FIG. 3 is a top plan view of the drawer with surrounding housing and swabs absent therefrom;

FIG. 4 is a top plan view of the carton housing in blank format; and

FIG. 5 is a top plan view of the carton drawer in blank format.

DETAILED DESCRIPTION OF THE INVENTION

Now we have devised a paperboard carton which allows dispensing of swabs from amongst a multi-row and multi-layer array yet minimizes contamination to the remaining non-dispensed bulk of swabs. The invention permits use of paperboard construction both for the outer housing and also the swab containing drawer. Exposure of the bulk of the swabs in a dispensing event is minimized by positioning the dispensing opening against a side wall of the housing rather than against the open mouth of the housing.

Further, the invention has identified the need for a drawer floor formed by at least three interleaved flaps. The interleaved flap number may range from 3 to 8, preferably from 3 to 5, and optimally 4 interleaved flaps. The interleaved construction of the floor must be able to have a strength for resisting a pressure of at least 30 pounds of force, particularly between 30 and 80, and optimally between 30 and 50 pounds of force.

An interleaved floor was found to insure a flat bottom surface upon which multiple rows/layers of swabs could be oriented without distortion of order. Although a single panel floor would have provided the same flat feature, this floor would have required a flap appendage folded and glued to a side panel. Test of this alternative (i.e. an “auto” bottom) resulted in hindered slidability. The glued flap caused hang-up in moving the drawer from the closed to the open position.

Interleaved flap construction does not hinder slidability. Moreover, with a construction that can resist 30 pounds of force (i.e. an at least three flap interleave) sufficient rigidity is maintained without distortion of the multiple rows and layers of swabs. Advantageously the layers may range from 3 to 50, preferably from 10 to 25, and optimally from 15 to 20 layers. The rows may number from 5 to 50, preferably from 10 to 25, and optimally from 15 to 20 rows of swabs. The pressure of at least 30 pounds of force avoids disturbing uniformity of the array. Visual aesthetics is thereby maintained. Also avoided is any problem of movement amongst the array caused by interference during sliding motion of the drawer. Moreover, a non-level floor that disrupts uniformity of the array can cause jamming in the process equipment that loads the drawer with swabs.

An advantage of utilizing a paperboard over a hardened plastic case is that the paperboard being initially a flat blank can receive print. Various designer graphics, logos and other aesthetically appealing features can be provided to outer surfaces of the housing. Differences in surface finishing may also add to the appeal of a paperboard construction.

FIG. 1 illustrates the dispensing carton 2 according to the present invention. The carton is formed of a housing 4 having a hollow receiving space 6 for slidably receiving a drawer 8. Within the drawer is an array of swabs 10.

A better understanding of the carton's construction can be understood from the blanks which when assembled form the housing and drawer. FIG. 4 illustrates via the housing blank the arrangement of the several walls that when assembled/glued together form the housing. A first wall 12 is flanked along parallel opposite fold lines 14, 16 by second walls 18, 20 respectively.

Mouth edge flaps 22 and 24 are joined by foot members 26 a, 26 b and 28 a, 28 b to the respective fold lines 30 and 32 of second side walls 18 and 20. A symmetrically curved window 34 and 36 is formed between flaps 22, 24 and the respective side walls 18 and 20.

Fold line 38 separates the second side wall 20 from the other first side wall 40. Further mouth edge flaps 42 and 44 are joined to respective first side wall 12 and first side wall 40 along respective fold lines 46 and 48.

A closure wall 50 is hingedly attached via fold line 52 to the first side wall 40 opposite to that of the further mouth edge flap 44. An end of the closure wall 50 features a tab 54 bendable along fold line 56. Closure flaps 58 and 60 of mirror image shape to one another flank the second side walls 18 and 20 respectively. These closure flaps border the second side walls along hinge lines 62 and 64 respectively and are opposite the edge flaps 22 and 24. Finally, the blank further features a tab 66 joining the first side wall 40 along a fold line 68.

Construction of the housing beginning with the flat blank occurs in the following manner. For definitional purposes the “top” surface is the surface shown in FIGS. 4 and 5; the “bottom” surface is on the non-viewed side of the blanks. Adhesives are applied to the top surfaces of flaps 22, 24, 42 and 44. These flaps are then bent along their respective fold lines 30, 32, 46 and 48. The bends will be 180 degree resulting in each of the aforementioned flaps adhering onto a top surface of the respective first and second side walls 12, 40, 18 and 20.

Thereafter, the fold lines 14, 16, 38 and 68 are bent at right angles to form the hollow receiving space. All top surfaces now form the interior surfaces of the receiving space. Tab 66 is treated with an adhesive on its bottom surface. During the folding process, tab 66 will adhere to the top, now interior, surface of the second side wall 18. This will lock the three-dimensional housing configuration.

A closed end of the receiving space is created by the bending of the closure wall 50, tab 54 and flaps 58, 60 at right angles inwardly toward the hollow receiving space. Closure wall 50 forms an outer perimeter of the housing with the flaps 58, 60 and with tab 54 oriented underneath.

Advantageously the bottom surface of all the flaps, first and second side walls and closure wall (which become exterior surfaces of the housing) can be coated with a gloss finish. Particularly preferred is an ultraviolet varnish finish. Advantageously, the gloss finish is characterized by a coefficient of friction allowing sheets to slide apart at an angle no higher than about 20 degrees. By contrast, the matte finish of the bottom surface of the drawer blank has a higher coefficient of friction allowing sheets to slide apart at an angle no less than about 25 degree.

The test for coefficient to friction is performed in the following manner. A base sample (size 70×100 mm) and a test sample (size 70×40 mm) are conditioned in a chamber with 50% relative humidity at 23° C. for 24 hours. Each test sample requires at least 10 duplicates. These are then evaluated on a Newton Instruments—“Torque and Friction Tester” having a Digital Level Meter or a TMI C.O.F. Tester 9825 with 1.65 lb., 2 inch×4 inch sled (or equivalent to provide 0.2 psi). Dependent upon the equipment, the angle of incline is recorded and tangent of angle is calculated (equals static coefficient to friction) or the C.O.F. is read directly from the Digital Level Meter.

Slidability of the drawer 8 is improved by the presence of the mouth edge flaps 22 and 24. Even though all remaining surfaces within the hollow receiving space of the housing are of a matte finish (slide angle 25 degree), the high glossed flap surfaces are sufficient to reduce friction (slide angle of 20 degrees). FIG. 2 best illustrates this aspect of the invention.

A better understanding of the drawer construction can be derived from considering the blank paperboard from which it is constructed. FIG. 5 illustrates the drawer blank. It features a pair of first side panels 70 and 72. A second side panel 74 adjoins the first side panel 70 along a fold line 76. A further second side panel 78 connects to each of the first side panels 70 and 72 along respective fold lines 80 and 82. A pair of mirror image flaps 84 and 86 flank respectively the first side panels 70 and 72 along fold lines 88 and 90. A locking flap 92 adjoins the second side panel 78 along fold line 94. The locking flap 92 features left and right arms 96 a and 96 b which are distant from fold line 94. Between the left and right arms is a gap area 98. A fourth flap 100 adjoins the second side panel 74 along fold line 102. Flap 100 features inward tapering edges 104 a, 104 b culminating in a truncated area 106.

A flap 108 lies adjacent the first side panel 70 along a fold line 110. Stop tab 112 adjoins the first side panel 72. A securing tab 114 adjoins the second side panel 74.

Assembly of the drawer may proceed as follows. A swab storage cavity 116 is created by bending at 90 degree angles the fold lines 76, 80 and 82. Adhesive is applied to the bottom surface of receiving tab 112 to secure locking of the first and second side panel for constructing the swab storage cavity. Concomitantly a floor 118 is formed as fold lines 88, 90, 94 and 102 are bent at right angles causing their interleaving. FIG. 3 illustrates floor 118 of the drawer. Here the interleaved flaps are shown in a preferred interlocking configuration. Truncated area 106 is received within gap area 98 and flaps 84 and 86 are similarly caused to lockingly interleave, the combination forming a securely held floor. Adhesive is applied onto the top surface of flap 108, the latter being bent 180 degree to adhere to the top surface of the first side panel 70. A dispensing opening 120 is formed as defined by edges 71, 73, 75 and 79 of panels 70, 72, 74 and 78, the edges being parallel and opposite that of fold lines 88, 90, 94 and 102. Swabs are deposited layer-wise through the opening into the cavity of the drawer. Upon full assembly the drawer is filled with the swabs and inserted into the hollow receiving space of the housing. 

1. A swab dispensing carton comprising: a housing defining a hollow receiving space and comprising a pair of parallel oppositely disposed first side walls, a pair of second side walls orthogonally oriented to the first side walls, a closure panel covering one end of the receiving space and at an opposite end an open mouth defined by upper edges of each of the first and second side walls; a drawer disposed within the hollow receiving space of the housing, the drawer comprising a pair of parallel oppositely disposed first side panels, a pair of second side panels orthogonally oriented to the first side panels, a floor orthogonally oriented to each of the first and second side panels, the floor comprising at least three interleaved flaps, the first and second side panels having respective upper edges defining a dispensing opening, the opening being juxtaposed opposite the floor; an array of swabs arranged within a cavity of the drawer; and wherein the floor has a strength to resist a pressure of at least 30 pounds of force, the drawer being slideably movable from an open to a closed position, the open position having the drawer partially outside the receiving space, and the dispensing opening being oriented to face one of the first or second side walls.
 2. The carton according to claim 1 further comprising a mouth edge flap adhesively attached to an interior surface of the second side wall.
 3. The carton according to claim 2 wherein the mouth edge flap has a coefficient of friction less than other areas of the interior surface of the second side wall.
 4. The carton according to claim 3 wherein the mouth edge flap comprises a pair of foot members straddling a curved window.
 5. The carton according to claim 1 wherein the array comprises from 10 to 25 layers and from 10 to 25 rows within each layer.
 6. The carton according to claim 1 wherein the interleaved flaps are four in number.
 7. The carton according to claim 6 wherein one of the interleaved flaps has a truncated area and is bounded by inward tapering edges.
 8. The carton according to claim 1 wherein one of the interleaved flaps has left and right arms bordering a gap area.
 9. A cardboard blank for a swab dispensing housing comprising: a first side wall; a second side wall adjoining the first side wall; a further second side wall adjoining the first side wall; a further first side wall adjoining the further second side wall; a mouth edge flap comprising left and right foot members, the foot members adjoining the second side wall; a curved window arranged between the mouth edge flap and the second side wall; a further mouth edge flap comprising further left and right foot members adjoining the further second side wall; a further curved window arranged between the further mouth edge flap and the further second side wall; and a pair of connected mouth edge flaps, a first of the connected mouth edge flaps being attached to the first side wall and a second of the connected mouth edge flaps being attached to the further first side wall.
 10. The cardboard blank according to claim 9 wherein a surface of the mouth edge flaps and connected mouth edge flaps are coated with a gloss finish. 